Aerospace

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Component: Manifold - Stainless Steel Product: Cross Hole Case Number:1002 Read More

Problem: The SAE J514 plugs had been known to back out in cross hole applications. The resulting leaks could not be tolerated in this aerospace application.

Use Description: The power unit manifolds were used to operate an actuator for a critical aerospace application.

Solution: The aerospace agency reviewed the performance characteristics of Zero-Leak Gold Plugs and specified that the -20 socket ZLGP be used in the power unit manifolds.

Results: The ZLGP were tested on the new project and they did not back out or leak.

Post Script: 62631

Component: Manifold, Hydraulic Product: Power Unit Case Number:1003 Read More

Problem: A manifold producer to the aerospace industry had discovered that the old style, O-ring only ORB plugs were backing out and of aluminum manifolds and causing leaks.

Use Description: The aluminum manifold waas component of a power unit used to drive an accuator attached to a launch vehicle.

Solution: The manifold producer specified in their prints that a -20 socket head Zero-Leak Gold Plugs be used in any future applications for the same unit.

Results: The aerospace facility install the -20 socket head ZLGP in their manifold. No leaks or backing out of plugs was reported in their application which had pressures as high s 10,000 psi. 62631

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Component: Manifold Product: - Case Number:1004 Read More

Problem: It was determined that the ports in the nickel plated manifolds being supplied to NASA had to have the ports that contained plugs re-tapped. If the ports were machined in the usual manner, they would have to have a new spot face. The new spot face would require nickel plating.

Use Description: Nickel plated manifolds that were used in a particular NASA application required some degree of modification to existing ports.

Solution: NASA personnel accepted their manifold supplier's advice and specified -06 and -08 Zero-Leak Gold socket head plugs for use in the nickel plated manifold. The ports were tapped and no new spot face was required because the ZLGP do not rely on the spot face for either of its two seals. Both of the ZLGP seals are internal to the port. The first is the metal to metal seal formed by the engagement of the complimentary tapers below the head of the plug and the taper at the entrance to the port. The second seal is the elastomeric seal located under the taper of the plug.

Results: The installation of the ZLGP avoided damaging the nickel plating by eliminating the necessity of machining the spot face. The ZLGP provided zero leak protection for the manifold. Both points resulted in cost savings for all involved.

Post Script: It is interestng to note that no special certifications were required of EPCO inorder for the ZLGP to be used in this application. This may be due to the fact that the standard old, O-ring only SAE straight thread plugs have some type of certifications and when their performance characteristics were compared to the documented* performance of ZLGP it became a "no brainer".

*Fluid Power Institute Test conducted at the Milwaukee School of Engineering. Click on 'FPI Test' at EPCO's home page to read the test.

62381

Component: Filter, Hydraulic Product: Filter, Housing Case Number:1014 Read More

Problem:The old style, O-ring only SAE plugs were observed backing out of test stands used on a previous project. Engineering was concerned about using these types of plugs in a new product. They wanted it to be "as perfect as possible".

Use Description: The hydraulic filter is used on mobile fluid carts and fluid power generation. It is extremely important that any potential for leakage is eliminated in products that are used in airfield related equipment.

Solution: The -04 hex head Zero-Leak Gold Plugs were installed as drain / fill plugs in the filter housings which in turn were sent to an internationally recognized, independent testing organization for a 1,000,000 cycle test.

Results: The Zero-Leak Gold Plugs completed the 1,000,000 test with no reported leaks. The old style, O-ring only SAE plugs were also evaluated and it was reported that they began 'seeping' at 600,000 cycles. The ZLGP were also subjected to burst tests at 15,000 psi with no reported leaks.

Post Script: The ZLGP became part of the new hydraulic filter design which was introduced in the market place. Another model filter is planned and it will utilize ZLGP.

62441

Automotive

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Component: Oil Line Manifold Block Product: - Case Number: 1010 Read More

Problem: New Product. Past experience with the SAE ORB O-ring exposure resulting in O-ring decay and eventual leaks. Even though they have not experienced leaks.

Use Description: Oil line manifold block has a port for oil pressure sensor which must be plugged.

Solution: Installed a socket head MS-S01V (M5 X 0.8)Zero-Leak Gold Metric plug with a Viton O-ring.

Results: Manufacturing is assured of a leak free engagement. O-ring is now protected from outer elements due to the unique, patented ZLGP design. All ZLGP provide dual seal protection.

Post Script: 62946

Component: Air Compressor for Suspension Product: Access Port Case Number: 1011 Read More

Problem: NPT plugs were being installed with a chemical sealant. It was felt that it was possible for the sealant to expose the system to contamination. It was reported that the NPT plugs backed out due to the possibility of the temperature change affecting the sealant.

Use Description: The plugs were used as a seal in an access port to an adjustment screw. The area must be kept dry and clean in order to prevent possible compressor failure.

Component:Injection Mold Plastic Product: Injection Mold Case Number: 1012 Read More

Problem: NPT plugs were leaking.

Use Description: The injection mold is cooled by oil. The mold reaches 320 degrees and the oil keeps the temperature uniform throughout the mold. The mold produces 4,000,000 pieces per year. Expansion and contraction causes the NPT joint to leak oil which contaminates the finished parts. There is no way to salvage the parts that have been contaminated and they become scrap.

Solution: The NPT ports in the mold were replaced with -03 SAE J1926 O-ring boss ports. An adaptor that has the Zero-Leak Gold design was used to create a 3" extension. A 22S-S03 socket head ZLGP was used.

Results: Leak free performance delivered less scrap, down time, exposure to environmental impact issues, and the work area safer for the employees.

Post Script: 63201 11/03

Communications

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Component: Fuel Cell / Power Back Up Systems Product: - Case Number: 1016 Read More

Problem: An aluminum manifold was plumbed with both SAE J1926 straight thread and NPT tapered thread ports. Both styles of ports had leaking hydrogen reported.

Use Description: Hydrogen containment in aluminum manifold using the old style SAE O-ring boss and NPT tapered threaded plugs. Chemical sealant was used on the NPT plugs. The leak problem was so severe that some of the plugs were welded in place at a cost $15.00 each. Still had leaks. They also tried some expensive ($11.00 each), brand name, stainless steel plugs that eventually backed out. More leaks.

Solution: Installed -02 and -05 mild steel socket head Zero-Leak Gold Plugs.

Results: No leaks have been reported. The total product was certified with the instructions from CSA (Canadian Standards Association)that if the ZLGP were replaced with another stlye, the product would have to go through certification again.

Post Script: Zero-Leak Gold Plugs will used in all future applications in order to eliminate the use of a chemical sealant and to replace fittings with unreliable sealing abilities.

62671

Diesel Engine

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Component: Oil Pan Drain Plug Product: Oil Pan Case Number: 1028 Read More

Problem: Plugs Backing Out.

Use Description: Diesel engine manufacturer was experiencing their SAE (J514)straight thread plugs were backing out in use and causing leaks. This was a serious problem with the engines that were supplied to the marine industry. The leaking fluids persented a high degree of exposure to environmental impact liability.

Solution: The manufacturer installed 22S-S05 non-magnet socket head Zero-Leak Gold Plugs.

Results: Oil pan leaks due to plugs backing out were eliminated.

Post Script: This particular manufacturer uses the non-magnet style ZLGP while others use a socket head ZLGP with a flush mounted magnet to remove metal particles from the system. The ZLGP is ideal for this application because its two seals don't leak, it doesn't require a chemical sealant and it can be removed and installed repeatedly without damage to the O-ring or to the threads of the ZLGP or port. The magnet style is available in all standard socket and hex head ZLGP.

Entertainment

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Component: Miscellaneous Hydraulic Components Product: - Case Number: 1052 Read More

Problem: Leaking Plugs Increased Safety Hazards & Liability Exposure.

Use Description: The Company designs, builds, installs, operates and maintains hydraulically operated special effects for their movies as well as rides & special effects for their theme parks world wide. The Company had experienced leaks at plug locations with various types of hydraulic components. There were many applications that may have caused pollution to waterways and other environmentally sensitive areas along with the expensive cleanup costs.

Solution: One of the Company's design engineers heard of the Zero-Leak Gold Plugs and requested samples for evaluation. The ZLGP provided the leak free operation desired. A conversion from existing J514 plugs to ZLGP was instituted during which the old style plugs were replaced with ZLGP. They specified that ZLGP be used on new hydraulic products or components that were ordered. The Company and their vendors use EPCO's website to get the latest specs on ZLGP.

Results: There have been no reported leaks wherever Zero-Leak Gold Plugs were installed.

Post Script: Some of the Company's hydraulic vendors are now using Zero-Leak Gold Plugs as standard items on their new products and as replacement parts to solve leaking plug problems with existing products in the field.

Farm Equipment

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Component: Manifold and SAE J514 plug Product: - Case Number: 1005 Read More

Problem: Leaks, environmental liability, maintenance and production issues.

Use Description: An agricultural implement manufacturer makes a piece of equipment that requires a manifold to be stacked on top of another. There are several ports in the manifolds that are not part of the design application and therefore must be plugged. Standard SAE J514 straight thread plugs presented various problems. The system's pressure spikes were instrumental in causing the SAE plugs to back out causing the hydraulic fluid to leak. Any fluid reaching the soil was unacceptable from operational, environmental and liability standpoints. The fluid leaking from between the stacked manifolds was unsightly and messy. There was a production issue that involved the stacking of the manifolds and their being placed in a size restrictive area. The high profile of the head of the SAE plug required that the top of the port be counter bored to lower the external profile of the head. Furthermore, the bottom of the top manifold had to be recessed to accommdate the head of the SAE plug installed in the manifold below.

Solution: Socket head Zero-Leak Gold Plugs were installed.

Results: No more leaks were reported. No more soil contamination or unsightly hydraulic fluid on the equipment or manifolds. Maintenance costs were greatly reduced. Manifolds nolonger need to be taken apart to replace leaking plugs. Over all cosmetic appearance improved. The low profile of the Zero-Leak Gold plugs made it possible to eliminate the deep counter bore on the bottom of the top manifold which resulted in reducing manufacturing costs.

Post Script:-

Component: Valve Hydraulic blocks and cylinders Product: Hydraulic Valve Block Case Number: 1006 Read More

Problem: The manufacturer had been using NPT plugs with a chemical sealant. Leakage was being reported. The sealant on the NPT plugs and port made removal and reinstallation difficult. It was necessary to heat the NPT plugs to remove them because a permanent type of sealant was being used.

Use Description: The hyraulic valve block / cylinder combination is used on agricultural machinery.

Solution: The NPT ports were replaced with the SAE J1926 straight thread port. Zero-Leak Gold -06 socket head plugs were installed.

Results: The ZLGP eliminated the leaks that had been present with the NPT plugs. Sealant was not necessary with the ZLGP and therefore the removal and re-installation became an easier process for all concerned.
62731

Post Script: 73842

Component: Drain/Fill Metric Magnetic Plug Product: - Case Number: 1007 Read More

Problem: This top 3 manufacturer was using standard metric straight thread plugs that were backing out and leaking. Would use chemical sealants and was concerned about system contamination due to removing and installing plugs to fill &/or clean off magnet.

Use Description:Used as drain / fill plug with a magnet to pull metal particles out of the system.

Solution: Installed Zero-Leak Gold M22 x 1.5 socket head metric plugs with flush mounted magnets.

Results: Solved leak and contamination problems. No chemical sealant required.

Post Script: Senior engineer indicated that all future products would contain the metric ZLGP with the flush mounted magnets. The metric size of the ZLGP is clearly engraved on the head of the ZLGP to easy and positive identification of its type and size.

Component: Cylinder, Hydraulic Product: - Case Number: 1008 Read More

Problem: Hex head NPT plug ports were reported leaking. The use of a chemical sealant in an attempt to prevent leakage made removal and installation extremely difficult.

Use Description: The NPT hex head plugs were used in hydraulic cylinder ports. The plugs were installed with a permanent type of chemical sealant. The NPT plugs had to be heated in order for them to be removed. Cleaning of the plugs and ports after removal and prior to re-installation was a concern.

Solution: The cylinder ports were changed to the SAE J1926 straight thread configuration so that -06 and -08 socket head Zero-Leak Gold Plugs could be installed.

Results: The Zero-Leak Gold Plugs have provided a higher quality product with a low profile plug. The ZLGP eliminated the leaks as well as the use of any type of chemical sealant which made removal and re-installation problems a non-issue.

Post Script: A new line of off the shelf Agricultural cylinders is being produced touting the benefits afforded by the use of Zero-Leak Gold Plugs.

62731

Forestry

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Component: O-ring only SAE plugs Product: Manifold Case Number: 1040 Read More

Problem: Vibration caused plugs to back out.

Use Description: O-ring only style SAE plugs were used in manifolds of tree cutters. There is high degree of vibration present during the operation of the equipment. This causes the plugs to back out and leak. The leaking fluid is an appearance problem on the equipment, could cause equipment failure, possible soil contamination with accompanying clean up and EPA ramifications.

Solution: -04 through -20 Zero-Leak Gold Plugs were installed in the new equipment and were used as replacements for leaking plugs in the field.

Results: No leaks have been reported wherever ZLGP were installed.

Post Script: -

Injection Molding

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Lawn Turf

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Component: Valve, hydraulic Product: Hydraulic Valve Case Number: 1039 Read More

Problem: The hydraulic valves supplied to the manufacturer of lawn care / mowing equipment were experiencing leaks at ports with SAE plugs. The plugs were backing out and causing fluid to leak in yards and on golf courses.

Use Description: The old style, O-ring only SAE plugs were used to plug port openings in hydraulic valves.

Solution: The manufacturer of the hydraulic valves recommended that the plugs used in the valves be changed to the socket head Zero-Leak Gold Plugs from the old style, O-ring only SAE plugs they had been supplying. No other changes such as engineering, manufacturing, etc. were required.

Results: The ZLGP eliminated the leaks.

Post Script: The lawn care equipment manufacturer has specified that other hydraulic equipment that they purchase have ZLGP installed as the plug of choice. The manufacturer also purchases ZLGP that are used to solve any leaking port problems that may arise in the field in product produced prior to the ZLGP conversion. One case in particular, made it possible to solve the problem on site instead of shipping the valves back for repair or replacement. The ZLGP are interchangable with the standard SAE straight thread plug which makes for a quick, easy and effective solution to what could have been a never ending cycle of leaks.

Machine Fixtures

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Component: Manifold Product: - Case Number: 1041 Read More

Problem: Old style SAE O-ring only plugs backing out.

Use Description: Aluminum hydraulic manifolds are produced for machine tool application. The final products are used in assembly line situations. 5,000 - 7,000 psi is involved. Vibration causes the plugs to back out leaking fluid on the machinery and surrounding floor area.

Solution: Zero-Leak Gold Plugs were installed.

Results: Leaks at plugged ports have been eliminated.

Post Script: -

Marine

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Component: NPT lubrication port plug Product: Engine Assembly Case Number: 1030 Read More

Problem: Threads collapse and the NPT plug backs out.

Use Description:NPT lubrication port plug is used regularly as part of the engine assembly. The working environment consists of 250 degree F and 1300 psi. The threads collapse and the plug backs out.

Solution:Switch from NPT to Zero-Leak Gold Plugs. Port already exists and only had to to modified with standard port tooling to accommodate the SAE compatible ZLGP.

Results: NO leaks and dramatically improved reliability.

Post Script: -

Material Handling

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Component: Steering and lift mast Product: Fork Lift Case Number: 1032 Read More

Problem: Old style O-ring only SAE plugs and JIC fittings were backing out in GPS guided fork lifts used in a food and beverage distribution center. the leaks initially went unnoticed and ultimately contaminated consumable food product resulting in product that had to be destroyed and fines from the Food and Drug Administration.

Use Description:The various size plugs are used to block unused ports in a manifold that feed the fork lift mast and steering gear. JIC fittings are used to plumb the tilt and lift functions of the fork lifts.

Solution:The old style O-ring only SAE plugs and JIC fittings were replaced with -04, -06 and -08 socket head Zero-Leak Gold Plugs and -04-04, -06-06, and -06-08 Zero-Leak Gold JIC fittings.

Results: The mechanical advantages resulting from the taper to taper engagement of the ports and the Zero-Leak Gold Plugs and fittings stopped the plugs and fittings from backing out due to vibration thereby eliminating the contamination of consumable food and beverage products and fines from the FDA.

Post Script:The distribution center was so pleased with the results achieved by the use of the Zero-Leak Gold Plugs and fittings they ordered an additional 15 GPS guided fork lifts from the manufacturer to be used in their distribution centers world wide.

63739

Component: Pump, Hydraulic Product: - Case Number: 1045 Read More

Problem: Old style, O-ring only SAE plugs were backing out in operation. The resulting leaks caused malfunctions in the operation of the pumps.

Use Description:The hydraulic pumps were installed in fork lift trucks which were used in industries where leaks of any kind could not be tolerated because of the environmental and contamination risks.

Solution:The fork lift company requested that the pump producer install Zero-Leak Gold Plugs in the pumps on order and provide ZLGP to replace the SAE plugs in the field that were backing out.

Results: Customized metric style Zero-Leak Gold Plugs were installed and the leak potential was eliminated.

Post Script: 62726

Medical

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Component: Dentist Chair Product: Dental Chair Case Number: 1027 Read More

Problem: Air pressure and water leaks. Loss of air pressure affects drill speed. Do not want water leaks to clean up in dentists' offices.

Use Description: The plugs used in the manifold in the dental chair account for air and / or water leaks.

Solution: Zero-Leak Gold -02 socket head plugs were installed in the chair manifold that has the air and water lines attached.

Results: Zero-Leak Gold -02 socket head plugs were installed and no leaks have been reported.

Post Script: -

Component: Manifold, Plastic Product: - Case Number: 1046 Read More

Problem: The high installation torque requirement of the old style, O-ring only SAE plugs was causing port thread damage in a plastic manifold used for a medical application. The result of a failure was life threatening.

Use Description: The plugs are used to block cross drills in a plastic manifold that feeds cleaning solution in a blood cleansing allocation.

Solution: The old style, O-ring only SAE plugs were replaced with Zero-Leak Gold socket head -02 and -03 plugs.

Results: The low torque needed to establish a seal with the Zero-Leak Gold Plugs eliminated thread damage of the port in the plastic manifold thereby preventing life threatening equipment failures.

Post Script: The successful switch to Zero-Leak Gold Plugs allowed the manufacturer to change all of their stainless steeel manifolds to plastic to realize substantial material cost savings while assuring there to be no system failures.

63730

Component: Hydraulic Cylinder Product: - Case Number: 1047 Read More

Problem: Producer of OEM medical equipment for skin treatment. System involved a refrigerant charged cylinder which used a test manifold for the detection of leaks. The plugs would back out and cause system leaks.

Use Description: Placed old style O-ring only plugs in the manifold and monitored for refrigerant leaks. Test could last several weeks during which some of the plugs would back out and result in a leaking system.

Solution: Installed -02 and -04 Zero-Leak Gold socket head plugs.

Results: The system leaks were eliminated.

Post Script: -

Military

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Component: Oil Pan Drain Plug Product: Oil Pan Case Number: 1029 Read More

Problem: Oil drain plugs were leaking in military vehicles with all the imaginable consequences.

Use Description: Plugs are in oil drain applications for vehicles used in all branches of the military.

Solution: Installed magnet style -08 socket head Zero-Leak Gold Plugs.

Results: The ZLGP do not back out and therefore, don't leak. The magnet allows particles to be held and then removed. The ZLGP may be removed and installed repeatedly without damaging the threads of either the plug or port. No chemical sealants are required and that prevents possible contamination from occurring. The metal-to-metal primary seal and elastomeric back up seal provide the maximum in leak prevention where it is needed most.

Post Script: -

Component: SAE O-ring only plug Product: Hydraulic Components Case Number: 1048 Read More

Problem: Current O-ring only plugs were leaking.

Use Description: The plugs are used in various hydraulic components that were ultimately used in military situations. The military is now mandating "no fluid leaks".

Solution: An aluminum -05 socket head Zero-Leak Gold Plug was selected to be used.

Results: No leaks have been reported.

Post Script: ZLGP were not on the military "approved" or "certified" list, but ZLGP solved the problems that were caused by the plugs on 'The' list. It was obvious that ZLGP not only are interchangeable with the SAE plugs, they outperform them.

Component: Old style SAE plug Product: Manifold Case Number: 1049 Read More

Problem: Plugs backing out of manifolds and caused leaks.

Use Description: Used in manifolds. The leaks are to be eliminated "by military order" and can not be tolerated in the end use application.

Solution: Took out the SAE plugs and installed Zero-Leak Gold Plugs.

Results: "Military orders" being followed...no leaks reported.

Post Script: -

Component: Hydraulic System Product: - Case Number: 1070 Read More

Problem: Plugs were backing out and causing leaks causing concern for system failure, environmental problems, and mechanical problems. Repairs required the sub to be raised and then lowered afterwards. This process involved about 3 hours.

Use Description: Stainless steel SAE straight thread plugs were used the hydraulic system.

Solution: -02 and -06 stainless steel Zero-Leak Gold Plugs were installed as replacements for the old style, O-ring only SAE plugs.

Results: No fluid leaks have been reported that caused the problems listed above.

Post Script: -

Component: Moisture removal equipment Product: - Case Number: 1071 Read More

Problem: Specific problem is unknown at this time, but it is believed that a quest for product improvement may have played a role in this matter.

Use Description: Under sea application with a fill plug.

Solution: -

Results: The producer's customer requested that the Zero-Leak Gold Plug be used based on past success and a more reliable multiple seal than the old style, O-ring only SAE straight thread plug.

Post Script: 62356

Motorcycle

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Component: SAE J514 plug for a case Product: - Case Number: 1051 Read More

Problem: Plugs backed out and leaked.

Use Description: Stainless steel SAE straight thread plugs were used the hydraulic system.

Solution: Installed -03 socket head Zero-Leak Gold Plugs with black oxide finish.

Results: No more plugs backing out. The low profile and the black oxide finish of the Zero-Leak Gold Plug complimented the general use area appearance in the end use application. The elimination of the leak location reduced potential warranty claims and boosted dealer and customer confidence.

Post Script: The ZLGP provided a competitive advantage since the other motorcycle manufacturer's products still leaked at this application point.

Off-Highway

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Component: Oil drum NPT plug Product: Oil Drum Case Number: 1019 Read More

Problem: The NPT plug on an oil drum was leaking after backing out which was caused by the vibration created by the compaction equipment.

Use Description: The oil drum was used to hold bearing lubricant on compaction equipment.

Solution: The drum was designed to accomodate the SAE J1926 straight thread port. Zero-Leak Gold socket head plugs were installed.

Results: No leaks were reported once the ZLGP were installed. The ZLGP design made it possible to remove and install the plugs as needed without damage to the threads of the port or plug. No chemical sealant was required. The O-ring remained intact during this process.

Post Script: -

Component: Manifold Product: Manifold Cross Hole Case Number: 1020 Read More

Problem: Old style, O-ring only SAE J514 plugs were reported leaking due to the deteriation of the O-ring caused by heat, pressure spikes of up to 10,000 psi and vibration.

Use Description: The SAE J514 plugs were installed in manifold cross holes. The manifolds were used in paving equipment of the construction industry.

Solution: The old style, O-ring only plugs were eliminated and replaced with -02, -04, -06, -08, -12, and -16 socket head Zero-Leak Gold Plugs. The ZLGP provided a low profile as well as a metal to metal seal with an O-ring back up seal.

Results: The manifold producer is using Zero-Leak Gold Plugs across the board for all of its applications. The ZLGP have eliminated the concerns that had existed with the previous plugs used.

Post Script: 62751

Component: Cylinder - Hydraulic Product: Hydraulic Cylinder Case Number: 1021 Read More

Problem: It was determined that a low profile and less expensive plug would better suit this particular application.

Use Description: Plugs were being used in the cylinder.

Solution: An engineering change was made to incorporate the Zero-Leak Gold Plugs into the product BOM.

Results: Zero-Leak Gold Plugs have become the "choice of the future" because of their quality and performance.

Post Script: The Zero-Leak Gold Plugs were recommended to an affiliated company where they were accepted and installed.

62421

Component: Oil Pan - Drain Plug Product: Differential Case Number: 1022 Read More

Problem: The plugs in both of the oil drain pan differtial loosen due to vibration. The resulting leaks cause equipment break downs. The problems were most evident in the compaction and material handling equipment product lines.

Use Description: The oil pans used the old style, O-ring only plugs. The operation of the equipment plus rough terrain caused vibration that resulted in the leaks.

Solution: The decision was made to install SAE straight thread magnet style Zero-Leak Gold Plugs. 22S-S08M

Results: Extensive tests (continuously running for 11 consecutive days) conducted by the user with the ZLGP installed showed no leak failures. The magnets added an additional benefit to help remove metal particles from the system. The ZLGP can be removed and installed repeatedly without damaging the threads of the plug or port nor the O-ring.

Post Script: The ZLGP have become standard items on all BOM's.

63425

Component: Directional Control Valve Product: - Case Number: 1031 Read More

Problem: SAE, old style, O-ring only -10 plugs leak due to deterioration and diestruction of the O-rings installed with the use of an impact wrench. Valves would have to be returned for repair.

Use Description: The SAE, old style, O-ring only -10 plugs are installed on directional control valves, which provide proportional control of both the movement and the force capability of hydraulic cylinders and motors.

Solution: Zero-Leak Gold -10 socket head plugs replaced the SAE type plugs.

Results: The ZLGP did not leak and the O-rings were damaged. The loss of valuable production time and costly repair labor due to leaking plug ports have been eliminated.

Post Script: -

Component: SAE O-ring only style drain plug on Product: Drain Plug Case Number: 1034 Read More

Problem: SAE O-ring only drain plugs were backing out and causing leaks. The drain plug is located in a difficult position to access for repair. It was reported that it could take up to 4 hours to remove and reinstall components. O-ring damage was observed.

Use Description: The gear boxes are used in fire fighting equipment. The SAE drain plugs were causing leaks @ 300 psi on the power divider which is a PTO unit connected to the transmission of the fire fighting equipment.

Solution: Zero-Leak Gold -04 socket head plugs were selected as replacements for the old SAE style.

Results: No leaks or O-ring damage have been reported.

Post Script: Lower ZLGP profile than the SAE plug was an added benefit in the product design.

Component: Drill bit / bearing grease Product: - Case Number: 1050 Read More

Problem: NPT plugs would back or their threads were stripped due to 90,000# of load with impact loads up to 2 1/2 times that amount.

Use Description: NPT plugs were installed along with a chemical sealant and used to contain the grease that was used to lubricate the drill bit bearings.

Solution: The ports were modified to the SAE J-1926 configuration and -04, -05 and -06 Zero-Leak Gold socket head plugs were installed.

Results: The ZLGP did not back out. The engagement of the complimentry taper under the head of the ZLGP and the taper in the port prevented damaging either the threads of the plug of the port in addition to providing the primary, metal to metal seal. The ZLGP were removable and could be installed repeatedly without any bearing contamination. No chemical sealant is used with ZLGP.

Post Script: 62411

Component: Manifold plug port leaking Product: - Case Number: 1055 Read More

Problem: An internationally known paving equipment company was observing the O-rings on the old style, O-ring only SAE plugs in their purchased aluminum manifolds backing out and causing leaks.

Use Description: The aluminum manifolds were being used in a 3-4,000 psi environment. The manifolds were being purchsed as complete assemblies.

Solution: The manifold producer was informed of the SAE O-rings extruding and the plug ports leaking. One of the manifold producer's engineers had used Zero-Leak Gold Plugs for some of their other customers. He sent a complete set of replacement Zero-Leak Gold Plugs to be installed in the manifolds that had been delivered to his customer.

Results: The assorted sizes of socket head Zero-Leak Gold Plugs were installed and there were no more O-ring extrusions reported at the plug ports.

Post Script: The paving company has requested that all future manifolds supplied to them have the Zero-Leak Gold Plugs installed as part of the assembly process.

Offshore Drilling / Oil Drilling / Downhole

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Component: Down Hole Tool Product: Fill Plug Case Number: 1053 Read More

Problem: NPT style plugs leaked due to being removed and installed repeatedly. The threads became worn. Chemical sealant was used in an attempt to prevent leaking oil out of the tool.

Use Description: The NPT plug was used in a fill plug application for oil in the down hole tool. The tool is used for drilling short, medium and high angle wells build rates up to 90 degrees / 100 feet.

Solution: The port configuration was changed to the standard SAE J1926. The -02 socket head Zero-Leak Gold Plug was installed.

Results: The ZLGP was used on several different occasions. The ZLGP eliminated the leaks that had been present when using the NPT plugs. Chemical sealant was not necessary. The removal and installation problems were eliminated due to the design of the ZLGP as it relates to the taper in the port.

Post Script: 52346-01

Component: Fill Valve Body - Submersable Motor Product: Motor Housing Case Number: 1054 Read More

Problem: The lead (soft metal) gasket on the motor housing failed and caused a leak in the motor housing.

Use Description: A lead (soft metal) gasket with a narrow span of torque limits was used in an effort to effect a seal. The seal was either over or under torqued and in both cases a leak resulted inside the motor housing. The leak caused the motor to fail. The result was to replace the motor and endure unwanted down time. Both were significant cost factors.

Solution: The Zero-Leak Gold design was incorporated into the body of the fill valve assembly.

Results: The lead gasket was eliminated. The assembly did not experience the previous leaks. Efficiency and reliability were increased and costs reduced. Motor life was no longer limited by leaking housings.

Post Script: -

Power Generation

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Racing

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Component: Engine Components Product: Engine Block Case Number: 1060 Read More

Problem: The plugs that were being used on the racing engines had a high profile that created close areas around various engine components. It was desireable that the plugs be removed and replaced without losing their sealing capacity.

Use Description: The application for the plugs is used in aluminum engine blocks used in racing.

Solution: An assortment of socket head aluminum and steel Zero-Leak Gold Plugs was installed. Since the socket head ZLGP seat in the port and not on the spot face of the port, it was possible for them to provide the desired low profile. ZLGP can be removed and re-installed repeatedly without the loss of their sealing ability and without damaging their O-rings.

Results: The low profile for the plug applications was accomplished along with the reliable sealing capacity when the plugs were removed and re-installed.

Post Script: 62636

Component: Racing Shocks Product: Shock Absorber Case Number: 1061 Read More

Problem: The NPT plugs that were being used required that a Teflon material be applied to the threads. This increased the cost of the application to about $1.00 to $1.50.

Use Description: Plugs are used to control or contain hydrogen and / or shock oil. They are used at the end of the shaft of the shock absorber for adjustment and fluid containment.

Solution: Several prototype ports were made using the SAE J1926 port. The -02 socket Zero-Leak Gold Plugs were installed without any type of sealing material.

Results: The Zero-Leak Gold Plugs performed to their expectations. This was done at a significant savings over the previous method. No problems have been reported from any of their customers.

Post Script: Due to the ease of installation and machining of the port, ZLGP will be used in all future designs.

62621

Component: Oil Pan Drain / Fill Plugs Product: Oil Pan Case Number: 1062 Read More

Problem: The manager of the company called seeking a product improvement for the race car oil pan drain plug.

Use Description: The plugs were used in the oil pans of race cars.

Solution: The -08 socket head Zero-Leak Gold Plugs in both steel and aluminum are being evaluated for their performance.

Results: An evaluation will be made at the end of the racing season.

Post Script: 62476

Railroad

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Component: NPT Plug Product: Manifold Case Number: 1063 Read More

Problem: The manufacturer of hydraulic / electronic components for the railroad industry was using NPT plugs and experiencing air pressure loss in the brake systems on their rail equipment. Loss of pressure placed heavy demands on the compressors which caused more maintenance and wear.

Use Description: The NPT plugs were used in aluminum manifold cross drilled NPT ports. The plugs may or may not be removed for access.

Solution: The manifolds were converted to SAE J1926 ports and Zero-Leak Gold Plugs were specified to eliminate the back out and pressure loss problems they had been experiencing.

Results: No air pressure loss while using ZLGP has been reported.

Post Script: -

Sanitary

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Component: SAE O-ring only style plug Product: - Case Number: 1065 Read More

Problem: Vibration caused plug to back out completely ceasing effectiveness of equipment.

Use Description: The plugs are used in conjunction with water and sewer line cleaning equipment. The "spray" plug in the nozzle would back out and become separated from the housing. Loss of pressure and cleaning effectiveness resulted. The operation would have to shut down until the plug was located and replaced.

Solution: Zero-Leak Gold Plugs were modified to create a spray pattern at the nozzle end of the cleaning fixture.

Results: The Zero-Leak Gold Plug remains in place and allows the cleaning to continue without shut downs for missing parts.

Post Script: -

Component: SAE plug Product: - Case Number: 1076 Read More

Problem: Vibration caused plugs to loosen and back out.

Use Description: The trench plow is used to make a trench in the ocean floor for communication cable. The process involves the use of robotics. The working environment temperature is about 35 degrees C and has moderate vibration. The plugs are installed in a bearing housing. Any leaks presented the opportunity for the creation of serious maintenance and scheduling problems. Either of these situations could be costly in money and time.

Solution: Zero-Leak Gold aluminum -04 socket head plugs were installed. The ZLGP are anodized.

Results: No leaks have been reported.

Post Script: -

SubSea

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Component: SAE plug Product: - Case Number: 1076 Read More

Problem: Vibration caused plugs to loosen and back out.

Use Description: The trench plow is used to make a trench in the ocean floor for communication cable. The process involves the use of robotics. The working environment temperature is about 35 degrees C and has moderate vibration. The plugs are installed in a bearing housing. Any leaks presented the opportunity for the creation of serious maintenance and scheduling problems. Either of these situations could be costly in money and time.

Solution: Zero-Leak Gold aluminum -04 socket head plugs were installed. The ZLGP are anodized.

Results: No leaks have been reported.

Post Script: -

Truck

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Component: Exhaust manifold plug Product: Exhaust Manifold Case Number: 1013 Read More

Problem: The NPT plugs were leaking in the exhaust manifolds.

Use Description: NPT plugs for the exhaust manifold was exposed to 1200 degrees F. The new manifold for light weight trucks required a plug that would not back out and also had to be able to be removed as needed.

Solution: A -10 socket head Zero-Leak Gold plug without an O-ring was installed. ZLGP resist the effects of vibration and do not back out.

Results: The ZLGP remain secure in the manifold without back out problems.

Post Script: -

Component: Custom plug Product: Heat Exchanger Case Number: 1036 Read More

Problem: The customer of the heat exchange manufacturer was concerned about the SAE O-ring only plug leaking in its trucks.

Use Description: The plug was used as a locator as well as a plug.

Solution: Incorporated the ZLGP design into the combination plug and locator.

Results: The Zero-Leak Gold plug design eliminated the leaks.

Post Script: Several other heat exchange companies are considering similar applications.

Component: Old style O-ring plug Product: Transmission Case Number: 1072 Read More

Problem: Aside from the plugs backing out, pieces of damaged O-rings were falling into the transmission. This resulted in partial transmission tear down to remove the particles.

Use Description: The plugs are are an important part of the transmission and were causing the problem when parts of the O-rings would stick to the port and fall into the transmission. It was a major job to take the transmission apart to remove the pieces of O-ring.

Solution: Zero-Leak Gold -04 socket head plugs were installed.

Results: The design of the Zero-Leak Gold plug prevents the O-ring from being damaged or nibbled and therefore, will not contaminate the transmission with O-ring particles. The low profile of the ZLGP proved to be advantageous to the design of the area in which the ZLGP is used. No more leaking plugs. The ZLGP is a standard item and therefore readily available to support their Kan Ban manufacturing process.

Post Script: -

Component: Drain / fill plug - square male drive Product: - Case Number: 1073 Read More

Problem: The SAE straight thread plugs with a chemical sealant that were being used leaked and the system was threatened with sealant contamination.

Use Description: The SAE plugs with a male square drive and chemical sealant were used in a drain / fill application for the transmissions.

Solution: A major truck customer of the transmission maker saw some custom -12 ZLGP that were being used by a competing transmission maker in other heavy duty truck applications. The customer requested that the same basic ZLGP design be used with the addition of the male square drive in transmissions supplied to them.

Results: The special ZLGP design was incorporated and the transmission leaks were eliminated.

Post Script: -

Component: Drain / fill plug Product: Transmission Case Number: 1074 Read More

Problem: Legislation has mandated that the Heavy Duty truck engines are to be more fuel efficient, have lower emissions, and no fluid leaks. Heavy Duty transmissions are to be designed as no leak. Existing truck transmissions still in service must be made leak free.

Use Description: Plugs are used for drain / fill applications in a new overdrive system.

Solution: A -08 socket head Zero-Leak Gold Plug will be installed as drain / fill plug in the overdrive case. The same ZLGP will be used for HD transmissions still in service.

Results: No fluid leaks at the ZLGP locations have been reported making the overdrive case leak free.

Post Script: -

Component: Drain / fill plug Product: Transmission Case Number: 1075 Read More

Problem: Legislation has mandated that the Heavy Duty truck engines are to be more fuel efficient, have lower emissions, and no fluid leaks. Heavy Duty transmissions are to be designed as no leak. Existing truck transmissions still in service must be made leak free.

Use Description: Plugs are used for drain / fill applications in a new overdrive system.

Solution: A -08 socket head Zero-Leak Gold Plug will be installed as drain / fill plug in the overdrive case. The same ZLGP will be used for HD transmissions still in service.

Results: No fluid leaks at the ZLGP locations have been reported making the overdrive case leak free.

Post Script: -

Wind Farm

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Component: Manifold Product: - Case Number: 1079 Read More

Problem: Leaking Manifolds = Expensive Maintenance Conditions / EPA Concerns

Use Description: A manufacturer of wind electric power generation equipment was experiencing SAE J514 style O-ring only plugs backing out of the manifolds that were installed in their equipment. The leaking created two unacceptable conditions. The first was that the leaking equipment was on a tower in excess of 150 feet in the air. Servicing / repair became a critical problem. The second was the environmental impact the leaking hydraulic fluid was causing on the desert surface below the towers.

Solution: The manufacturer of the SAE J514 style plugs that were backing out recommended that the manufacturer contact EPCO and consider replacing the original SAE plugs with Zero-Leak Gold Plugs.

Results: The original SAE plugs were replaced with Zero-Leak Gold Plugs. No leaks have been reported. No leaking manifolds and no environmental impact liability attributed to leaking plugs.

Post Script: -

Work Holding

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Component: SAE plug Product: - Case Number: 1080 Read More

Problem: Vibration caused plug to back out.

Use Description: Hydraulic equipment is used to secure dies and fixtures in place in press (metal stamping) work. Vibration caused SAE plugs to back out of the ports in the hydraulic cylinder. The fluid leaked on the equipment, floor and finished product causing down time, clean up and less than perfect finished product. This increased clean up time and lowered production output.

Solution: The older SAE O-ring only stlye of plugs was removed and the multiple seal Zero-Leak Gold Plugs were installed.

Results: No ZLGP back out and no more fluid leaks. Labor cost reductions and productivity improvement.

Post Script: Zero-Leak Gold Plugs are clearly visible in their product brochure.

Misc

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Industry: PrintingComponent: Rotary Die Product: - Case Number: 1059 Read More

Problem: Metal shavings were damaging the die.

Use Description: The application was new and Zero-Leak Gold Plugs with rare earth magnets installed were selected to remove the metal shavings.

Solution: Hex head -04 Zero-Leak Gold Plugs with rare earth magnets were installed.

Results: The metal shavings were collected and there was no report of any rotary die damage due to shavings. The low profile of the ZLGP proved to be a functional benefit.

Post Script: 62646

Industry: Sewer EquipmentComponent: SAE O-ring only style plug Product: - Case Number: 1065 Read More

Problem: Vibration caused plug to back out completely ceasing effectiveness of equipment.

Use Description: The plugs are used in conjunction with water and sewer line cleaning equipment. The "spray" plug in the nozzle would back out and become separated from the housing. Loss of pressure and cleaning effectiveness resulted. The operation would have to shut down until the plug was located and replaced.

Solution: Zero-Leak Gold Plugs were modified to create a spray pattern at the nozzle end of the cleaning fixture.

Results: The Zero-Leak Gold Plug remains in place and allows the cleaning to continue without shut downs for missing parts.

Post Script: -

Industry: Skid SteelComponent: Drive Motor - Hydraulic Product: Drain Plug Case Number: 1066 Read More

Problem: The fill / drain SAE J514 plug used by an overseas location of an international company was backing out due to vibration causing O-ring extrusion and leaks.

Use Description: A SAE J514 ORB -04 socket head plug was used in the drive motor as the fill / drain plug.

Solution: Personnel involved checked with their counterparts at other manufacturing locations as to their experience with ZLGP. These recommendations added support to the decision to install socket head -04 Zero-Leak Gold Plugs as the fill / drain plug.

Results: No ZLGP have been reported to back out and therefore there have been no O-ring extrusions with the accompanying leaks.

Post Script: Future drive motor applications will have Zero-Leak Gold Plugs performing the fill / drain function.
62081

Industry: Steel MillComponent: Roller Pipe Product: - Case Number: 1068 Read More

Problem: The SAE straight thread with O-ring roller pipe would back out and let water escape. This caused constant mopping.

Use Description: The roller pipe is part of a steel coiling system. 1200 degree F steel ingots are sent from the furnace through a series of rollers that flatten the steel to a desired thickness and coiled at the end of the process.

Solution: The Zero-Leak Gold design replaced the SAE threaded end of the roller pipe.

Results: No leaks from any of the ZLG roller pipes have been reported.

Post Script: -

Industry: Street SweeperComponent: Manifolds Product: - Case Number: 1069 Read More

Problem: SAE plugs were backing out of the manifold causing leaks.

Use Description: Aluminum manifolds were being used in the system. The manifolds were installed in hard to get areas for service or repair. The SAE straight thread plugs were backing out due to vibration and pressure spikes. The resulting leaking was not acceptable and the repair process was costly. The repairs were only temporary since once the interface leaked, it had a tendency to repeat the process later.

Solution: When the manifold producer was informed of the problem they contacted EPCO and asked that some Zero-Leak Gold plugs be sent to their customer to solve the problem. Since Zero-Leak Gold plugs are interchangeable with SAE J514 style plugs, it was a simple matter to take out the SAE plugs that had leaked and replace them with Zero-Leak Gold plugs.

Results: The leak problem was solved and the manifold producer began installing Zero-Leak Gold plugs in their manifolds.

Post Script: One other major customer of that manifold company liked the performance of the Zero-Leak Gold plugs so well that it referred two of its other hydraulic component suppliers to EPCO so they could supply their products to it with the Zero-Leak Gold plugs installed.